Integrated speaker assembly for personal media device

ABSTRACT

Systems and methods are provided for media devices including a housing, a frame disposed adjacent to the housing, and an acoustic source that is integrated with the frame for emitting sound from the media device.

REFERENCE TO RELATED APPLICATIONS

This application is co-pending with Docket No. 104677-0045-101, entitled“Integrated Microphone Assembly for Personal Media Device,” filed onJan. 5, 2007, the entire contents of which are incorporated herein byreference.

BACKGROUND

This invention relates to personal media devices and, more particularly,to integrated speaker assemblies for personal media devices.

The proliferation of compact portable personal media devices (e.g.,portable MP3 players, portable video players, and media capable cellulartelephones) has created a need for delivery of audio (e.g., voice andmusic) via more durable, reliable, and robust audio sources to userswhile respecting the need to minimize the overall form factor ofpersonal media devices.

One problem with existing media devices such as cellular telephones isthat the media device's acoustic source, e.g., a speaker assembly, issusceptible to external forces that can damage subassembly componentssuch as a diaphragm, electric components, or the housing. For example, ahand-held media device may be dropped by a user. An impact, even from arelatively short distance, could result in structural damage to aspeaker assembly mounted on an internal printed circuit board (PCB) ormounted to the housing of the media device. Additionally, a gasket thatprovides a seal between the speaker assembly and device housing couldbuckle or become deformed due to the impact, resulting in reducedacoustic coupling from the acoustic source to the external aperture ofthe device. Accordingly, there is a need for mounting an acousticsource, such as a speaker assembly, in such a way as to reduce thesusceptibility of the source to physical stress resulting from, forexample, a physical impact on the device or “drop shock.”

Another problem with existing media devices is that the structuralrigidity of the acoustic source or its surrounding components ormaterials may not be sufficient to adequately mitigate the effects ofvibrations. For example, vibrations induces from another acousticsource, a user, an alarm, or another vibration source could adverselyeffect, introduce interference, or reduce the acoustic coupling from anacoustic source to the external aperture of the media device.Accordingly, there is a need for enhanced structural rigidity of theacoustic source or its surrounding materials to enable the acousticsource to more efficiently couple audio to the external housing apertureof a media device while mitigating the effects of vibration or otherinterference.

SUMMARY

The invention, in various embodiments, addresses deficiencies in theprior art by providing systems, methods and devices that enhance theability of the acoustic source to withstand physical stresses andenhance sound quality while respecting the need for a compact andportable form factor for such devices.

In various aspects, the invention employs an acoustic source, e.g., aspeaker assembly, in a media device. The acoustic source is integratedwith at least a portion of the frame of the media device. Because aframe provides structural support for the media device, the framegenerally has greater structural strength than, for example, a housingor internal circuit board of the media device. By integrating theacoustic source with a frame having greater structural strength andintegrity, the ability of the acoustic source to withstand physicalstresses or vibrations is enhanced. The term “integrated with” mayinclude integrally formed with, unitarily formed with, attached to,detachably connected to, mounted on, or any like permanent,semi-permanent, or temporary configuration whereby the acousticassembly, or a portion thereof, is in physical communication or contactwith the frame of the media device.

In one aspect, a media device includes a housing, a frame disposedadjacent to the housing, and an acoustic source that is integrated withthe frame for emitting sound from the media device. The frame may bedisposed substantially within the housing. The frame may include asidewall or plurality of sidewalls. At least one sidewall may include anaperture in acoustic communication with the acoustic source.

The frame may include a backplane. A portion of the acoustic source maybe positioned substantially on a top surface of the backplane. A portionof the acoustic source may be enclosed within an upper casing where theupper casing is attached to the frame. Also, a portion of the acousticsource may be positioned substantially on a bottom surface of thebackplane. A portion of the acoustic source may be enclosed within anlower casing where the lower casing is attached to the frame. The framemay be connected to the housing using at least one gasket.

Another aspect of the invention includes a method for manufacturing amedia device. The method includes providing a housing, attaching a frameto the housing, and integrating an acoustic source with the frame. Theintegration may include inserting an acoustic source within a recess ofthe frame. In one feature, an upper casing is mounted to the frameproximate to the acoustic. In another feature, a lower casing is mountedto the frame proximate to the acoustic source.

Various advantages and applications using an acoustic source integratedwith a media device frame in accordance with principles of the presentinvention are discussed in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention, its nature andvarious advantages will become more apparent upon consideration of thefollowing detailed description, taken in conjunction with theaccompanying drawings, in which like reference characters refer to likeparts throughout, and in which:

FIG. 1A is a perspective view of a media device with an exposed frameassembly according to an illustrative embodiment of the invention;

FIG. 1B is another perspective view of a media device according to anillustrative embodiment of the invention;

FIG. 2 shows the media device of FIGS. 1A and 1B with tetheredheadphones and, alternatively, a wireless earpiece according to anillustrative embodiment of the invention;

FIG. 3 shows a simplified functional block diagram of a media deviceaccording to an illustrative embodiment of the invention;

FIG. 4 shows a transverse sectional view of a conventional cellulartelephone;

FIG. 5 shows an exploded perspective view of the various sections of aconventional cellular telephone including a frame;

FIG. 6 shows a transverse sectional view of a media device according toan illustrative embodiment of the invention;

FIG. 7 shows a cross-sectional view of an acoustic assembly according toan illustrative embodiment of the invention.

FIG. 8 shows a perspective view of a frame including an integratedacoustic assembly according to an illustrative embodiment of theinvention;

FIG. 9 shows a transverse sectional view of a portion of a media deviceincluding an acoustic assembly that is integrated with a frame accordingto an illustrative embodiment of the invention; and

FIG. 10 is a flow chart of a process for manufacturing a media deviceaccording to an illustrative embodiment of the invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

FIG. 1A is a perspective view of a media device 100 according to anillustrative embodiment of the invention. The media device 100 includesa housing 102, a first housing portion 104, a second housing portion106, a display 108, a keypad 110, a speaker housing aperture 112, amicrophone housing aperture 114, a headphone jack 116, and framesidewall 122. Although not shown, in certain embodiments, the framesidewall 122 is the exposed portion of a frame residing within oradjacent to the housing 102 that provides structural support for themedia device 100 and various internal components. The housing 102 alsoincludes various gaps 118 that may include openings, separations, vents,or other pathways between elements of the housing 102 that enable thepassage of air or sound through the housing 102.

In one embodiment, the housing 102 includes a first housing portion 104and a second housing portion 106 that are fastened together to encasevarious components of the media device 100. In certain embodiments, thehousing 102 also includes an exposed frame 120 that provides structuralsupport for the media device 100. The housing 102 and its housingportions 104 and 106 may include polymer-based materials that are formedby, for example, injection molding to define the form factor of themedia device 100. In one embodiment, the housing 102 surrounds and/orsupports internal components such as, for example, one or more circuitboards having integrated circuit components, internal radio frequency(RF) circuitry, an internal antenna, a speaker, a microphone, a harddrive, a processor, and other components. Further details regardingcertain internal components are discussed later with respect to FIG. 3.The housing 102 provides for mounting of a display 108, keypad 110,external jack 116, data connectors, or other external interfaceelements. The housing 102 may include one or more housing apertures 112to facilitate delivery of sound, including voice and music, to a userfrom a speaker within the housing 102. The housing 102 may including oneor more housing apertures 114 to facilitate the reception of sounds,such as voice, for an internal microphone from a media device user.

In certain embodiments, the housing 102 includes one or more gaps 118associated with the housing 102. These gaps 118 may result from themanufacturing and/or assembly process for the media device 100. Forexample, in certain circumstances, the mechanical attachment of thefirst housing portion 104 with the second housing portion 106 or thesidewall 122 results in a crease 120 or joint between the portions 104and 106. In certain media devices 100, the crease 120 is not air tight,resulting in gaps 118 along the crease. Other gaps may be formed duringassembly between, for example, one or more keys of the keypad 110 andthe housing 102 or the display 108 and the housing 102, resulting inadditional gaps 118. In other embodiments, the housing 102 may includeaddition portions that are integrated to form the housing 102 for themedia device 100.

The media device 100 may include a wireless communications device suchas a cellular telephone, satellite telephone, cordless telephone,personal digital assistant (PDA), pager, portable computer, or any otherdevice capable of wireless communications. In fact, FIG. 1 shows anexemplary cellular telephone version of a broad category of media device100.

The media device 100 may also be integrated within the packaging ofother devices or structures such a vehicle, video game system,appliance, clothing, helmet, glasses, wearable apparel, stereo system,entertainment system, or other portable devices. In certain embodiments,device 100 may be docked or connected to a wireless enabling accessorysystem (e.g., a wi-fi docking system) that provides the media device 100with short-range communicating functionality. Alternative types of mediadevices 100 may include, for example, a media player such as an iPodavailable by Apple Computer Inc., of Cupertino, California, pocket-sizedpersonal computers such as an iPAQ Pocket PC available by HewlettPackard Inc., of Palo Alto, Calif. and any other device capable ofcommunicating wirelessly (with or without the aid of a wireless enablingaccessory system).

In certain embodiments, the media device 100 may synchronize with, forexample, a remote computing system or server to receive media (usingeither wireless or wireline communications paths). Wireless syncingenables the media device 100 to transmit and receive media and datawithout requiring a wired connection. Media may include, withoutlimitation, sound or audio files, music, video, multi-media, and digitaldata, in streaming and/or discrete (e.g., files and packets) formats.

During synchronization, a host system may provide media to a clientsystem or software application embedded within the media device 100. Incertain embodiments, media and/or data is “downloaded” to the mediadevice 100. In other embodiments, the media device 100 is capable ofuploading media to a remote host or other client system. Further detailsregarding the capabilities of certain embodiments of the media device100 are provided in U.S. patent application Ser. No. 10/423,490, filedon Apr. 25, 2003, the entire contents of which are incorporated hereinby reference.

FIG. 1B is another perspective view of a media device 100 according toan illustrative embodiment of the invention. In this embodiment, asopposed to the embodiment of FIG. 1A, the media device's frame and/orthe frame's sidewalls are not exposed to an external surface of thedevice. However, in certain embodiments, the frame is connectedinternally with at least a portion of one of the first housing portion104 or the second housing portion 106.

FIG. 2 shows the media device 100 of FIG. 1 with tethered headphones 200and, alternatively, a wireless earpiece 206 according to an illustrativeembodiment of the invention. The tethered headphones 200 include a cable212 that connects to the media device 100 via external jack 116. In oneembodiment, the cable provides for transport of an audio signal from themedia device 100 to the headphones 100. In another embodiment, theheadphones 200 includes a left housing 202 and a right housing 204,corresponding to the left and right ears of a user, respectively. Eachhousing 202 and 204 may include a speaker and/or an acoustic assembly asdescribed later with respect to FIG. 4. The headphones 200 mayoptionally include a microphone to facilitate sending sounds from theuser to the media device 100. As an alternative to the headphones 200, auser may utilize the wireless earpiece 206 which includes a housing 208.In one embodiment, the earpiece 206 employs wireless channel 210 toreceive audio signals from the device 100 or transmit audio signals tothe device 100. The housing 208 may include a speaker, microphone,and/or acoustic assembly as described later with respect to FIG. 4.

FIG. 3 shows a simplified functional block diagram of the media device100 according to an illustrative embodiment of the invention. The mediadevice or player 300 may include a processor 302, storage device 304,user interface 308, display 310, CODEC 312, bus 318, memory 320,communications circuitry 322, a speaker or transducer 324, and amicrophone 326. Processor 302 may control the operation of manyfunctions and other circuitry included in media player 300. Processor302 may drive display 310 and may receive user inputs from userinterface 308.

Storage device 304 may store media (e.g., music and video files),software (e.g., for implanting functions on device 300, preferenceinformation (e.g., media playback preferences), lifestyle information(e.g., food preferences), exercise information (e.g., informationobtained by exercise monitoring equipment), transaction information(e.g., information such as credit card information), wireless connectioninformation (e.g., information that may enable media device to establishwireless communication with another device), subscription information(e.g., information that keeps tracks of podcasts or television shows orother media a user subscribes to), and any other suitable data. Storagedevice 304 may include one more storage mediums, including for example,a hard-drive, permanent memory such as ROM, semi-permanent memory suchas RAM, or cache.

Memory 320 may include one or more different types of memory which maybe used for performing device functions. For example, memory 320 mayinclude cache, ROM, and/or RAM. Bus 318 may provide a data transfer pathfor transferring data to, from, or between at least storage device 304,memory 320, and processor 302. Coder/decoder (CODEC) 112 may be includedto convert digital audio signals into an analog signal for driving thespeaker 324 to produce sound including voice, music, and other likeaudio. The CODEC 112 may also convert audio inputs from the microphone326 into digital audio signals.

User interface 308 may allow a user to interact with the media device300. For example, the user input device 308 can take a variety of forms,such as a button, keypad, dial, a click wheel, or a touch screen.Communications circuitry 322 may include circuitry for wirelesscommunication (e.g., short-range and/or long range communication). Forexample, the wireless communication circuitry may be wi-fi enablingcircuitry that permits wireless communication according to one of the802.11 standards. Other wireless network protocols standards could alsobe used, either in alternative to the identified protocols or inaddition to the identified protocol. Other network standards may includeBluetooth, the Global System for Mobile Communications (GSM), and codedivisional multiple access (CDMA) based wireless protocols.Communications circuitry 322 may also include circuitry that enablesdevice 300 to be electrically coupled to another device (e.g., acomputer or an accessory device) and communicate with that other device.

In one embodiment, the media device 300 may be a portable computingdevice dedicated to processing media such as audio and video. Forexample, media device 300 may be a media player (e.g., MP3 player), agame player, a remote controller, a portable communication device, aremote ordering interface, an audio tour player, or other suitablepersonal device. The media device 300 may be battery-operated and highlyportable so as to allow a user to listen to music, play games or video,record video or take pictures, communicate with others, and/or controlother devices. In addition, the media device 300 may be sized such thatit fits relatively easily into a pocket or hand of the user. By beinghandheld, the media device 300 (or media device 100 shown in FIG. 1) isrelatively small and easily handled and utilized by its user and thusmay be taken practically anywhere the user travels.

As discussed previously, the relatively small form factor of certainprior art media devices has constrained the ability of these mediadevices to protect certain acoustic components such as speaker ormicrophone assemblies from damaging physical forces. Also, the qualityof sound emitted from an acoustic source or received by an acousticreceptor has been adversely effected by the supporting structure orstructures for these acoustic components. For example, a speaker that ismounted on a circuit board may be susceptible to vibrations that arepropagated along the circuit board structure which can introduceinterference or noise into the speaker's sound output. Accordingly,embodiments of the invention provide for improved sound quality andenhanced structural support for acoustic components such as an acousticsource.

FIG. 4 shows a transverse sectional view of a conventional cellulartelephone 400. The conventional cellular telephone 400 comprises anupper housing 402. The main structural frame 404 is secured to thehousing 402 which may be fabricated from a die-castable material using adie-casting process. The frame 404 includes a surrounding sidewall 406and a web or backplane 408. The web 408 extends between the sidewall 406and forms a printed circuit board compartment between the housing 402and web 408. The printed circuit board compartment is bounded on the topby the housing 402 and on the bottom by the web 408. The printed circuitboard compartment includes a printed circuit board 410 and associatedelectrical components 412. The web 408 supports or houses a battery 414which, in turn, forms the back of the cellular telephone 400. Theconventional cellular telephone 400 employs a unitized frame member 404which is composed of a single die-castable material, typically magnesiumor zinc, where the sidewall 406 and the web 408 are constructed of thesame or different material via a die-cast fabrication technique.

FIG. 5 shows an exploded perspective view of the various sections of aconventional cellular telephone 500 including a frame 502. The cellulartelephone 500 generally comprises an upper enclosure or housing 504, aprinted circuit board 506, the structural frame member 502, and abattery 508. As shown in FIG. 5, there are a number of features formedon the housing 504 that correspond with components located on theprinted circuit board 506. For example, disposed on the exterior face ofthe housing 504 is a display panel aperture 510 that corresponds with adisplay panel 512 disposed on the printed circuit board 506.

Adjacent to the display panel aperture 510 is an earphone or speakeraperture 514 that corresponds with a speaker component or assembly 516on the printed circuit board 506. Also disposed on the face of thehousing 504 is an array of keypad apertures 518 that corresponds with atactile keypad component 520 mounted on the printed circuit board 506. Amicrophone aperture 522 is located adjacent the keypad apertures 518that corresponds with a microphone component or assembly 524 which ismounted on the printed circuit board 506.

The cellular telephone 500 includes a structural frame 502, that alsoincludes a surrounding sidewall 526 and a web or backplane 528. Anantenna receptacle 530 is formed as part of the frame 502 that enablesthe transfer of radio frequency (RF) communications with the enclosedprinted circuit board 506. The sidewall 526 is formed through adie-casting process using material such as magnesium or zinc or alloysof each. The term die-cast typically refers to a structure formed by aprocess wherein the casting material is melted into a liquid phase andpoured into a die-cast mold. The casting material then assumes the shapeof the mold upon cooling and solidification.

The backplane 528 typically includes a thin, high strength formedstructure, such as a plate of stainless steel. A formed structuretypically includes components that have been stamped, pressed, punched,rolled or otherwise fabricated while the formed material is in a solidphase. The thin plate or backplane 528 is typically secured to thesidewall 526 using a mechanical or die-casting technique.

The backplane 528 typically extends between the surrounding sidewall 526and divides the enclosed interior space into a printed circuit boardcompartment and a battery compartment. The printed circuit boardcompartment is typically bounded on the top by the housing 504, and onthe bottom by the backplane 528. The printed circuit board compartmenttypically contains the printed circuit board 506 and various associatedelectrical components. The backplane 528 also acts as an upper boundaryfor the battery compartment. The battery pack 508 can be attached to theframe 502 and forms the back of the cellular telephone 500. It should beunderstood that the frame 528 typically establishes front and backcompartments on each side of the backplane 528.

FIG. 6 shows a transverse sectional view of a media device 600 accordingto an illustrative embodiment of the invention. The media device 600comprises an upper housing 602, lower housing 604, a frame 606, aprinted circuit board 608, printed circuit board components 610, and anacoustic source 612. In one embodiment, the acoustic source 612 isintegrated with the frame 606 and includes an acoustic subassembly 622,an upper casing 624, a lower casing 626, and casing seals 628. The frame606 includes a sidewall or sidewalls 614 and a backplane 616. In oneembodiment, the main structural frame 606 is secured to at least one ofthe upper housing 602 and lower housing 604. At least a portion of thehousings 602 and 604 may be fabricated from a die-castable materialusing a process including die-casting, molding, injection-type molding,and/or the like.

In one embodiment, the frame 606 includes a surrounding sidewall 614 orplurality of sidewalls 614 and a web or backplane 616. The web 616extends between the sidewall 614 or between two or more sidewalls 614 toform a printed circuit board compartment 618 between the upper housing602 and the web 616. Thus, the printed circuit board compartment 618 maybe bounded on the top by the upper housing 602 and on the bottom by theweb 616. In certain embodiments, the sidewall 614 extends completelyalong the perimeter of the frame 606. Alternatively, the sidewall 614extends along one or more portions of the perimeter of frame 606,effectively forming a plurality of sidewalls 614. In one embodiment, theframe 606 does not have a sidewall 614, but is connected to orintegrated with at least one of the upper housing 602 and the lowerhousing 604 or integrated with at least one of the first housing portion104 and the second housing portion 106 of the media device 100.

In certain embodiments, the web 616 and lower housing 604 form a secondcompartment 620 that contains a battery and/or electrical components.The media device 600 may employ a unitized or composite frame 606 thatincludes a die-castable or other material, such as steel, magnesiumand/or zinc, or related alloys, where the sidewalls 614 and the web 616are constructed of the same or different materials via a die-cast and/orassembly fabrication technique. The assembly fabrication technique mayinclude connecting one or more portions of the frame 606 together usingglue, one or more mechanical connectors, or another like attachmentmechanism or medium.

In certain embodiments, the acoustic source 612, e.g., a speakerassembly, is integrated with the frame 606 as shown in FIG. 6. Asprevious discussed, the acoustic source 612 includes an acousticsubassembly 622, an upper casing 624, a lower casing 626, and casinggaskets or seals 628. The acoustic subassembly 622 may be, for example,a speaker subassembly including a diaphragm and other speakercomponents. By integrating the acoustic source 612 with the frame 606,the frame 606 advantageously protects the acoustic subassembly 622components from external forces and/or mitigates the effects ofvibration or other interference.

In one embodiment, the frame 606 includes a recess 630 within which theacoustic subassembly 622 is disposed. In another embodiment, theacoustic source 612 includes an upper casing 624 that is disposed abovethe acoustic subassembly 622. In a further embodiment, the acousticsource 612 includes a lower casing 626 that is disposed below theacoustic subassembly 622. One or more casing seals may be employed tofasten either or both the upper casing 624 and the lower casing 626 tothe frame 606. Because the upper casing 624 and the frame 606 form anupper volume 632 and the lower casing 626 and frame 606 form a lowervolume 634, the upper and lower volumes 632 and 634 may be adjusted byadjusting the size of the upper and lower casings 624 and 626respectively. By adjusting the size of the volumes 632 and 634, thequality of sound emitted by the acoustic source 612 may be adjusted. Inone embodiment, the seals 628 include adhesive to enable the casing 624and/or 626 to connect with the web and/or sidewall of frame 606.

In an alternative embodiment, the acoustic source 612 is integrated withthe frame 606 substantially within the upper casing 624. The acousticsource 612 may include an upper and lower volume, or other volumes,substantially within the upper casing 624. In another alternativeembodiment, the acoustic source 612 is integrated with the frame 606substantially within the lower casing 626. The acoustic source 612 mayinclude an upper and lower volume, or other volumes, substantiallywithin the lower casing 626. Thus, in certain embodiments, the frame 606includes a casing for an acoustic source 612 on either its top or bottomside as opposed to on both sides of the frame 606.

Although FIG. 6 shows the acoustic source 612 being integrated with theframe 606 while contacting both the sidewall 614 and web 616, theacoustic source 612 may be positioned at any one of a plurality ofpossible positions on the web 616 and/or between the sidewalls 614. Inone embodiment, the upper and lower casings 624 and 626 are connected tothe web 616, with or without casing seals 628. The size and shape of theacoustic source 612 and the casings 624 and 626 may vary depending onthe available space, desired sound quality, and positioning of othercomponents in the media device 600. For example, the shape of theacoustic source 612 may be, without limitation, rectangular, circular,helical, spherical, stepped, or any other shape dictated by surroundingcomponents and/or other design requirements.

The frame 606 may include one or more apertures, cutouts, openings,and/or recesses to support the acoustic source 612. In one embodiment,the sidewall 614 includes at least one aperture to enable the transportof sound from the acoustic source 612 to outside of the media device600.

FIG. 7 shows a cross-sectional view of an acoustic source 700 accordingto an illustrative embodiment of the invention. The acoustic source 700includes an acoustic subassembly 702, a first chamber 704, a secondchamber 706, a housing 708, a first lateral wall 710, a second lateralwall 712, a retaining wall 714, an output aperture 716, a first sourceaperture 718, a second source aperture 720, a first transfer aperture722, a second transfer aperture 724, and a leak aperture 726. A user'sear 728 is typically positioned in proximity to the output aperture 716to enable the user to receive sound, e.g., voice or music, from theaperture 716. The acoustic subassembly 702 may include a micro-speakersuch as a speaker in the 2403 Receiver family manufactured by NXPSemiconductors of Eindhoven, The Netherlands.

In certain embodiments, the acoustic source 700 is included within, forexample, the housing 102 of the media device 100 as shown in FIG. 1. Inone embodiment, the housing 708 corresponds to the housing 102 ofFIG. 1. Thus, the first chamber 704 may be a cavity, void, space, orenclosure within the housing 102. Also, the second chamber may be asecond cavity, void, space, or enclosure within the housing 102. In oneembodiment, the retaining wall 714 is a portion of the web 616 of theframe 606 of FIG. 6. In other embodiments, at least one of the firstlateral wall 710, a second lateral wall 712, a retaining wall 714, anoutput aperture 716, a first source aperture 718, a second sourceaperture 720, a first transfer aperture 722, a second transfer aperture724, and a leak aperture 726 is integrated with a frame such as frame606 of FIG. 6. In certain embodiments, the acoustic subassembly 702emits sound through at least one aperture such as apertures 718 and 720into the first chamber 704. In one embodiment, the second chamber 706 isin contact with or directly coupled to the acoustic subassembly 702.Either chamber 704 or 706 may be filled with air, a gas mixture otherthan air, a liquid, or other acoustically permeable material. Theacoustic subassembly 702 may include a transducer, a speaker, or amicro-speaker. The acoustic subassembly 702 may be referred to as anacoustic receiver which is distinct from an RF receiver.

In one embodiment, the size or area of the leak aperture 726 is derivedfrom plurality of actual apertures or gaps 118 in the housing 102 (asshown in FIG. 1). In certain embodiments, the effective area of the leakaperture 726 is calculated, measured, and/or algorithmically modeledfrom an aggregation of the gaps 118 to estimate the effective leak rateof sound from the second chamber 706. In one embodiment, the secondchamber 706 includes a cavity within the housing 708 (or housing 102 ofFIG. 1) other than the volume of the chamber 704. Thus, the effectivearea of the aperture 726 may include the sum of the areas of all of thegaps 118 of the housing 102. Because, in certain embodiments, the mediadevice 100 is manufactured and/or assembled using a repeatable and/orpredictable process with consistent component dimensions, the effectivearea and/or leak rate of the aperture 726 can be predicted and/orestimated within a reasonable tolerance for every media device 100.Thus, for example, the volume of the first chamber 704 or the area ofthe apertures other than the effective aperture 726 may be configured tooptimize the tuning of the sound emitted from the aperture 716 for alarge volume of media devices 100.

In another embodiment, the acoustic subassembly 702 is disposed in aposition that overlaps or is adjacent to only a portion of the outputaperture 716. To direct sound or sound waves from the acoustic source702 to the aperture 716, the acoustic subassembly 702 employs the firstchamber 704, i.e., a front cavity, which is defined by the lateral walls710 and 712 and the retaining wall 714 that extends between the lateralwalls 710 and 712. The retaining wall may include at least one transferaperture such as apertures 722 and 724 that permit sound waves to flowfrom the first chamber 704 to the second chamber 706. The transferapertures 722 and 724 may be considered leak apertures from the firstchamber 704. In one embodiment, the second chamber 706 includes theinternal volume of the media device 100 other than the volume of thefirst chamber 704. To provide an outlet for sound waves that have leakedinto the chamber 706, a plurality of apertures (represented conceptuallyas leak aperture 726) may be disposed throughout the housing of themedia device (e.g., gaps 118). Alternatively, one or more gaps 118 maybe selectively machined through the housing 708 to adjust the effectiveleak aperture 726 size.

In one embodiment, the retaining wall 714 provides a surface to whichthe acoustic subassembly 702 is affixed. The retaining wall 714 may be aportion of a backplane or web 616 as shown in FIG. 6. The retaining wallmay include apertures such as source apertures 718 and 720 that permitthe flow of sound waves from the acoustic subassembly 702 into the firstchamber 704. In certain embodiments, the transfer or internal leakapertures 722 and 724 permit improved control of the acoustic quality ofthe sound emitted from the aperture 716.

In certain embodiments, the housing 708 is defined by the upper and/orlower casings 624 and 626 of FIG. 6. In other embodiments, the housing708 is defined by either the upper casing 624 or the lower casing 626.Thus, for example, the first chamber 704 may be defined by an uppercasing 624 while the second chamber 706 is defined by the an innervolume of the media device 100 because a lower casing 626 is notpresent. In another example, only the lower casing 626 may be presentwherein the acoustic subassembly resides in the second chamber 706.Thus, the first chamber 704 is defined as a portion of the volume of thehousing 102 which may include, for example, the printed circuit boardcompartment 618 as shown in FIG. 6. In one embodiment, the aperture 716is included in a portion of the frame 606. More particularly, theaperture 716 may reside within a sidewall 614 of the frame 606, or inthe skin of a media device that is adjacent to the frame 606, andthereby enable the coupling of sound to outside of a media device suchas media device 100. In an alternative embodiment, the aperture 716 maycouple sound to an intermediate chamber for subsequent coupling viaanother aperture to outside of the media device 100. Further detailsregarding various embodiments of the acoustic source 700 are describedin further detail in U.S. Patent application Ser. No. ______, filed onDec. 21, 2006, entitled “Acoustic Assembly for Personal Media Device,”the entire contents of which are incorporated herein by reference.

FIG. 8 shows a perspective view of a frame 800 including an upper casing802 and a lower casing 804 for supporting an integrated acoustic sourceaccording to an illustrative embodiment of the invention. In oneembodiment, the upper and lower casings 802 and 804 are connected to thebackplane or web 806 of the frame 800. In addition to providing supportand shock protection to an enclosed acoustic subassembly, the casings802 and 804 provide increased structural support and integrity to theframe 800 itself. In another embodiment, a portion of at least the upperand lower casings 802 and 804 are connected to a sidewall or sidewalls808 of the frame 800. The frame 800 may include a backplane 806 thatextends between sidewalls 808. Although shown as solid sheet or plane ofmaterial, the backplane 806 may include one or more openings, cut-outs,or voids. In one embodiment, the frame 800 includes only sidewall 808with substantial no backplane 806. In another embodiment, the backplane806 includes sections or portions that are stepped or shift verticallyfrom one another. In yet another embodiment, the frame 800 includes aplurality of backplanes 806 or has portions wherein a plurality ofbackplane sheets overlap or are positioned in parallel with one another.For example, in one embodiment, the backplane section 810 overlapsand/or is positioned in parallel with the backplane 806, both of whichare portions of the frame 800. In a further embodiment, a multilayeredframe 800 provides increased firmness and structural integrity for amedia device and its various components.

FIG. 9 shows a transverse sectional view of a housing portion 900 of amedia device including an acoustic source 902 that is integrated with aframe 904 according to an illustrative embodiment of the invention. Theacoustic source 902 includes an acoustic subassembly 906, an uppercasing 908, and casing seals or gaskets 910. The housing portion 900also includes a housing shell or skin 912 having a plurality of outputapertures 914 in a grill pattern. The frame 904 also includes seals orgaskets 916. The acoustic subassembly 906 may further employ one or moregaskets for mounting on the frame 904. Because the acoustic subassembly906 is disposed within or adjacent to the frame 904, relatively shortgaskets, with respect to conventional gaskets, may be employed betweenthe acoustic subassembly 906, the frame 904, and the skin 912 to cushionthe acoustic subassembly 906 from external forces that could damage orcause interference with the acoustic subassembly 906 components. Withoutthe frame 904 between the acoustic subassembly 906 and/or the skin 912,a longer gasket is required that is susceptible to buckling when exposedto sufficient external force. Once a gasket buckles or is deformed, thegasket's ability to, for example, couple sounds efficiently is reduced.In contrast, the shorter gaskets 910 and/or 916 are able to withstandgreater external forces and, therefore, are less susceptible to bucklingand deformation due to physical shock. In certain embodiments, the widthor thickness of a gasket is less than about 1.5 mm, less than about 1.25mm, less than about 1 mm, less than about 0.75 mm, less than about 0.5mm, less than about 0.25 mm, less than about 0.125 mm, less than about0.1 mm, less than about 0.075 mm, and/or less than about 0.05 mm.Accordingly, by employing these relatively shorter gaskets 910 and 916,a media device becomes more robust and reliable with respect to physicalstresses and for delivering quality sound 918.

In certain embodiments, as shown in FIG. 9, the acoustic source 902 isable to provide sound 918 to an output aperture 914 along a curvedsurface of the skin 912 because the acoustic source 902 can bepositioned away from the skin 912. The acoustic source 902 can bepositioned a distance away from the skin 912 because the acoustic source902 is integrated with and/or supported by the frame 902.

FIG. 10 is a flow chart of a process 1000 for manufacturing a mediadevice according to an illustrative embodiment of the invention. Theprocess 1000, in one embodiment, includes providing a media devicehousing such as housing 102 of FIG. 1 (Step 1002). Then, attaching aframe such as frame 800 to the housing (Step 1004). Also, an acousticsource such as acoustic source 902 is integrated with the frame toenable the delivery of sound outside of a media device such as mediadevice 100 (Step 1006). The integration of the acoustic source with theframe may include mounting an acoustic subassembly to the frame and thenmounting either or both an upper and lower casing to the frame whereinthe acoustic subassembly resides.

It is understood that the various features, elements, or processes ofthe foregoing figures and description are interchangeable or combinableto realize or practice the invention describe herein. Those skilled inthe art will appreciate that the invention can be practiced by otherthan the described embodiments, which are presented for purposes ofillustration rather than of limitation, and the invention is limitedonly by the claims which follow.

1. A media device comprising: a housing, a frame disposed adjacent tothe housing, and an acoustic source being integrated with the frame foremitting sound from the media device.
 2. The device of claim 1, whereinintegrated with includes detachably connected to.
 3. The device of claim1, wherein integrated with includes unitarily formed with.
 4. The deviceof claim 1, wherein integrated with includes mounted to.
 5. The deviceof claim 1, wherein the frame is disposed substantially within thehousing.
 6. The device of claim 1, wherein the frame includes asidewall.
 7. The device of claim 6, wherein the sidewall includes anaperture in acoustic communication with the acoustic source.
 8. Thedevice of claim 1, wherein the frame includes a backplane.
 9. The deviceof claim 8, wherein a portion of the acoustic source is positionedsubstantially on a top surface of the backplane.
 10. The device of claim9, wherein a portion of the acoustic source is enclosed within an uppercasing, the upper casing being attached to the frame.
 11. The device ofclaim 8, wherein a portion of the acoustic source is positionedsubstantially on a bottom surface of the backplane.
 12. The device ofclaim 11, wherein a portion of the acoustic source is enclosed within anlower casing, the lower casing being attached to the frame.
 13. Thedevice of claim 1, wherein the frame is connected to the housing usingat least one gasket.
 14. A method for emitting sound from the housing ofa media device comprising: integrating an acoustic source with a frameof the media device, and emitting sound from the acoustic source to anexternal aperture of the housing.
 15. The method of claim 14, whereinintegrating includes detachably connecting to.
 16. The method of claim14, wherein integrating includes unitarily forming with.
 17. The methodof claim 14, wherein integrating includes mounting to.
 18. The method ofclaim 14 comprising disposing the frame substantially within thehousing.
 19. The method of claim 14, wherein the frame includes asidewall.
 20. The method of claim 19, wherein the sidewall includes anaperture in acoustic communication with the acoustic source.
 21. Themethod of claim 14, wherein the frame includes a backplane.
 22. Themethod of claim 21 comprising positioning a portion of the acousticsource substantially on a top surface of the backplane.
 23. The methodof claim 22 comprising enclosing a portion of the acoustic source withinan upper casing, the upper casing being attached to the frame.
 24. Themethod of claim 21, comprising positioning a portion of the acousticsource substantially on a bottom surface of the backplane.
 25. Themethod of claim 24 comprising enclosing a portion of the acoustic sourcewithin an upper casing, the upper casing being attached to the frame.26. The method of claim 21 comprising connecting the frame to thehousing using at least one gasket.
 27. A method for manufacturing amedia device comprising: providing a housing, attaching a frame to thehousing, and integrating an acoustic source with the frame.
 28. Themethod of claim 27, wherein integrating includes inserting an acousticsource within a recess of the frame.
 29. The method of claim 28, whereinintegrating includes mounting an upper casing to the frame proximate tothe acoustic source.
 30. The method of claim 29, wherein integratingincludes mounting a lower casing to the frame proximate to the acousticsource.